Accessory Harness & Bracket Kit

Transcription

1 Accessory Harness & Bracket Kit Stainless Steel Hopper Spreader Gas 9969 June 5, 06 Lit. No , Rev. 0 PARTS LIST VIB LIGHT STROBE PREWET Accessory Harness & Bracket Kit Item Part Qty Description Item Part Qty Description 9899 Relay/Fuse Assy Bracket Gas ns Accessory Cable Assy Hopper Side Dash Bracket Kit ns Accessory Cable Assy Vehicle Side Rocker Switch ns Accessory Switch Harness Assembly ns Bolt Bag Accessory Harness Kit ns 5K " Battery Cable Red Bolt Bag Accessory Harness Kit 4 3* /4 0 x 3/4 Hex Cap Screw SS 9 /4 0 x / Hex Cap Screw G Isolated Stud Block/Fuse Holder 0 #0 Clamp Loop x / Pan-Head Machine ns A Fuse Screw SS ns Cable Tie Long Locknut GB ns Position Jumper Assembly 8 6 /4 0 Locknut GB ns = not shown G = Grade SS = Stainless Steel * Additional / x 3/4 hex cap screws in bolt bag not used for this application. A DIVISION OF DOUGLAS DYNAMICS, LLC

2 INSTALLATION INSTRUCTIONS WARNING Do not exceed GVWR or GAWR ratings as found on the driver-side vehicle door cornerpost. 3. One of the two supplied fuse holders will serve as an isolated stud block. Install the isolated stud block to the relay/fuse assembly bracket using two #0 x /" pan head machine screws and #0 locknuts. Read this document before installing the Accessory Enclosure and Harness. #0 Locknut Use standard methods and practices when attaching spreader and installing accessories, including proper personal protective safety equipment. Park the vehicle on a smooth, level, hard surface, such as concrete. Turn the vehicle ignition to the "OFF" position and remove the key. Install Hopper-Side Accessory Cable Assembly. Unlatch the engine cover rubber hold down straps and open the cover.. Install the relay/fuse assembly bracket to the engine mount as shown using two /4" x 3/4" cap screws, one /4" x /" cap screw, and /4" locknuts. Relay/Fuse Assembly Bracket /4" x /" Cap Screw /4" x 3/4" Cap Screw Isolated Stud Block #0 x /" Machine Screw 4. Route the hopper-side accessory cable to the accessory bracket, coming in from the passenger side on the forward (hopper) side of the engine. Make sure that the engine cover will not contact the cable when the cover is closed. 5. Remove the cover of the isolated stud block. Connect the ring terminal on the accessory cable's red wire to the top stud and the ring terminal on the black wire to the bottom stud. 6. Slip a supplied clamp loop onto the hopper side accessory cable. Remove and retain the nut for the existing fastener securing the engine harness to the engine mount. Position the accessory cable assembly and its clamp loop over the existing fastener, and reinstall the nut to secure both cables. 7. Once the desired spreader accessories have been installed, replace the cover on the isolated stud block and close and latch the engine cover. Engine Mount /4" x 3/4" Cap Screw /4" Locknut Lit. No , Rev. 0 June 5, 06

3 Install Vehicle-Side Accessory Cable Assembly. Before beginning this installation, disconnect the battery cables from the vehicle battery.. Position the supplied fuse holder near the vehicle battery so the " red battery cable can reach both the POSITIVE (+) battery terminal and the fuse holder. Install the fuse holder using /4" x 3/4" cap screws, 4" flat washers, and /4" locknuts. Hand tighten the nuts. 8. Connect the other end of the " battery cable to the POSITIVE (+) battery terminal. Connect the black wire from the vehicle-side accessory cable to the NEGATIVE ( ) battery terminal. NOTE: When using a 50" or 90" battery cable, connect the black wire from the vehicle-side accessory cable to a ground bolt on the vehicle frame or engine. Clean off any paint or dirt to ensure a good connection. 9. Reconnect the vehicle battery cables. NOTE: An accessory 50" or 90" battery cable may be installed in place of the standard " cable for applications requiring a longer cable. 3. Remove the fuse holder cover. Remove the lock washers and nuts from both studs. Insert the supplied 60-amp fuse. Connect one end of the battery cable to one of the fuse holder studs so that the ring terminal is on top of the fuse. 4. Lay out a path for routing the vehicle-side accessory cable from the rear of the truck bed to the vehicle battery, making sure avoid any hot, sharp, or moving parts of the truck. Routing may vary from truck to truck. 5. Route the vehicle-side accessory cable as laid out in Step 4. Secure the vehicle accessory cable assembly to the truck using cable ties. Verify that the cable assembly cannot drop onto the road when it is disconnected from the spreader. 6. Connect the red wire from the vehicle-side accessory cable to the second fuse holder stud so that the ring terminal is on top of the fuse. Replace the lock washers and nuts on both studs. 7. Tighten the fuse holder nuts to in lb. Snap the fuse holder cover back in place. Lit. No , Rev. 0 3 June 5, 06

4 Install Accessory Switch Harness When installing the accessory switch dash bracket, choose a location that is within easy reach of the vehicle operator without restricting access to vehicle controls or vehicle instrumentation. Do not mount the control in areas prohibited by the vehicle manufacturer for crashworthiness. See the vehicle's body builder's book, owner's manual or service manual for details. The shaded areas in the illustration below show the most commonly restricted areas. Do not alter, modify or install additional components in shaded areas shown below. Failure to comply may interfere with airbag deployment or cause injury to operator in an accident. Before drilling any holes, check both sides of the material for any wires, fuel lines, fuel tanks, etc. that may be damaged by drilling. 3. Drill a 5/8" hole in the fire wall so the accessory switch harness can reach to the desired switch bracket location. 4. Insert the supplied rubber grommet into the hole. 5. Route the accessory switch harness as laid out in Step. 6. Secure the accessory switch harness to the truck using cable ties 7. Plug the accessory switch harness's connector into the mating connector on the vehicle side accessory cable assembly. (Refer to the Vehicle Side Harness Diagram on page 7.) NOTE: Use dielectric grease on all electrical connections.. Lay out a path for routing the accessory switch harness from its connection with the vehicle accessory cable assembly into the cab of the truck. Make sure the path avoids any hot, sharp, or moving parts of the truck. Routing may vary from truck to truck.. Identify a convenient location for the accessory switch bracket that can be reached by the accessory switch harness. The bracket has two sets of mounting holes so it can be installed on either a horizontal or a vertical surface. Lit. No , Rev. 0 4 June 5, 06

5 Install Switch Bracket and Switches. Position the switch bracket at the previously selected location in the vehicle cab. Before drilling any holes, check both sides of the material for any wires, fuel lines, fuel tanks, etc. that may be damaged by drilling.. Using the switch bracket as a template, drill three 7/3" holes that align with the mounting holes in the top or rear face of the bracket. 3. Install the switch bracket using three #0 x 3/8" tapping screws, #0 lock washers and #0 hex nuts. 4. Install the 4 rocker switches into the switch bracket with the red surface facing up. Gently push the switches into the rectangular holes until they snap into place. 5. Strip /4" of insulation from the white, orange, blue, and gray non-terminated accessory switch harness wires and crimp a female push-on terminal onto each prepared wire. (Refer to the Vehicle Side Harness Diagram on page 7.) 6. Connect the colored wires to the rocker switch terminals as follows: WHITE strobe lights ORANGE pre-wet system BLUE vibrator GRAY work light GREEN (extra switch) 7. Strip /4" of insulation from the black wire in the accessory switch harness and crimp it onto the insulated butt splice connecter of the 4-position jumper assembly. Connect the push-on terminals of the 4-position jumper to the remaining terminals of the rocker switches. #0 Hex Nut Red surface facing up. #0 Lock Washer Rocker Switch #0 x 3/8 Tapping Screw Lit. No , Rev. 0 5 June 5, 06

6 HOPPER-SIDE HARNESS DIAGRAM YEL Isolated Stud Block (shown with cover removed) RED BA Work/Strobe Lights BA Accessorv Relay/Fuse Assemblies (Not included in 9969 kit.) RED RED YEL BLU ( ) Common ORN Pre-Wet WHT Strobe GRY Work Light BLU Vibrator GRN Extra Vibrator Accessory Cable Assembly Hopper Side Lit. No , Rev. 0 6 June 5, 06

7 VEHICLE-SIDE HARNESS DIAGRAM Fuse Holder w/60a Fuse RED " RED CABLE Accessory Cable Assembly Vehicle Side NEG POS Battery Accessory Switch Harness Assembly ( ) Common ORN WHT Insulated Butt Splice GRY BLU GRN Extra Dealer-Installed Terminals SW SW SW3 SW4 Vibrator Work Light Strobe Light Pre-Wet 4-Position Jumper Assembly Lit. No , Rev. 0 7 June 5, 06

8 Copyright 06 Douglas Dynamics, LLC. All rights reserved. This material may not be reproduced or copied, in whole or in part, in any printed, mechanical, electronic, film or other distribution and storage media, without the written consent of the company. Authorization to photocopy items for internal or personal use by the company's outlets or spreader owner is granted. The company reserves the right under its product improvement policy to change construction or design details and furnish equipment when so altered without reference to illustrations or specifications used. This equipment manufacturer or the vehicle manufacturer may require or recommend optional equipment for spreaders. Do not exceed vehicle ratings with a spreader. The company offers a limited warranty for all spreaders and accessories. See separately printed page for this important information. Printed in U.S.A. Lit. No , Rev. 0 8 June 5, 06